Fibrous body manufacturing apparatus, fibrous body manufacturing method, ground sheet, and functional sheet

ABSTRACT

A fibrous body manufacturing apparatus includes a putting-out unit, a transportation unit, a deposition unit, and a pressing and heating unit. The putting-out unit puts a ground sheet out, with a functional member arranged on one side of a sheet. The transportation unit transports the ground sheet put out onto itself. The deposition unit lets fibers and a binder deposit on one side of the transported ground sheet, thereby forming a web thereon. The pressing and heating unit applies pressure and heat to the web.

The present application is based on, and claims priority from JPApplication Serial Number 2020-162203, filed Sep. 28, 2020, thedisclosure of which is hereby incorporated by reference herein in itsentirety.

BACKGROUND 1. Technical Field

Embodiments of the present disclosure relate to a fibrous bodymanufacturing apparatus, a fibrous body manufacturing method, a groundsheet, and a functional sheet.

2. Related Art

In related art, the use of a special kind of paper called as securitypaper has been proposed as one methods for enhancing security, forexample, as disclosed in JP-A-2020-097802. Security paper is, forexample, produced by embedding magnetic wires that exhibit a largeBarkhausen effect in a sheet material in a papermaking process. When analternating magnetic field having a predetermined frequency is appliedto this type of paper, the magnetic wire embedded in the paper causessteep magnetization reversal. By detecting the magnetization reversalusing a detection device installed in, for example, a gate, it ispossible to detect the presence of the paper that includes the magneticwires.

However, magnetic wires embedded in such security paper, in someinstances, could become exposed on the surface of the paper. If magneticwire exposure occurs, the performance of printing on the paper willdeteriorate when the paper is used for a print purpose.

SUMMARY

A fibrous body manufacturing apparatus according to a certain aspect ofthe present disclosure includes: a putting-out unit that puts a groundsheet out, with a functional member arranged on one side of a sheet; atransportation unit that transports the ground sheet put out ontoitself; a deposition unit that lets fibers and a binder deposit on oneside of the transported ground sheet, thereby forming a web thereon; anda pressing and heating unit that applies pressure and heat to the web.

A fibrous body manufacturing method according to a certain aspect of thepresent disclosure includes: putting a ground sheet out, with afunctional member arranged on one side of a sheet; transporting theground sheet put out; letting fibers and a binder deposit on one side ofthe transported ground sheet, thereby forming a web thereon; andpressing and heating the web.

A ground sheet according to a certain aspect of the present disclosureis to be used by a fibrous body manufacturing apparatus and includes: asheet; and a functional member arranged on one side of the sheet;wherein the ground sheet has a roll shape.

A functional sheet according to a certain aspect of the presentdisclosure includes: a sheet; a functional member; an adhesive layerthat bonds the functional member to the sheet; and a concealing layerprovided on a surface of the adhesive layer and configured to hide theadhesive layer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a fibrous body manufacturing apparatusaccording to a first embodiment.

FIG. 2 is a schematic view of a putting-out unit of the fibrous bodymanufacturing apparatus according to the first embodiment.

FIG. 3 is a schematic view of the putting-out unit of the fibrous bodymanufacturing apparatus according to the first embodiment.

FIG. 4 is a schematic plan view of a sheet according to the firstembodiment.

FIG. 5 is a schematic cross-sectional view of a sheet according to thefirst embodiment.

FIG. 6 is a schematic plan view of a sheet according to the firstembodiment.

FIG. 7 is a schematic plan view of a sheet according to the firstembodiment.

FIG. 8 is a flowchart for explaining a method for manufacturing afibrous body according to the first embodiment.

FIG. 9 is a schematic view of a fibrous body manufacturing apparatusaccording to a second embodiment.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

With reference to the accompanying drawings, a certain non-limitingadvantageous embodiment of the present disclosure will now be explainedin detail. The specific embodiment described below shall never beconstrued to unduly limit the scope of the present disclosure recited inthe appended claims. Not all of components described below necessarilyconstitute indispensable parts of the present disclosure.

1. First Embodiment 1.1. Fibrous Body Manufacturing Apparatus 1.1.1.Overall Configuration

First, with reference to the accompanying drawings, a fibrous bodymanufacturing apparatus according to a first embodiment will now beexplained. FIG. 1 is a schematic view of a fibrous body manufacturingapparatus 100 according to a first embodiment.

As illustrated in FIG. 1, the fibrous body manufacturing apparatus 100includes, for example, a supplying unit 10, a coarse crushing unit 12, adefibrating unit 20, a screening unit 40, a first web forming unit 45, arotator 49, a mixing unit 50, a deposition unit 60, a second web formingunit 70, a sheet forming unit 80, and a cutting unit 90.

The supplying unit 10 supplies a raw material to the coarse crushingunit 12. For example, the supplying unit 10 is an automatic feeder forsuccessive inputs of a raw material into the coarse crushing unit 12.The raw material supplied by the supplying unit 10 contains fibers, forexample, fibers of waste paper or pulp sheets.

The coarse crushing unit 12 shreds the raw material supplied by thesupplying unit 10 into small pieces under atmospheric conditions, forexample, in air. The small pieces are, for example, pieces of a fewsquare centimeters. In the illustrated example, the coarse crushing unit12 has coarse crushing blades 14, and is able to shred the inputted rawmaterial by means of the coarse crushing blades 14. For example, ashredder is used as the coarse crushing unit 12. After shredding by thecoarse crushing unit 12, the raw material is received by a hopper 1, andis sent to the defibrating unit 20 through a pipe 2.

The defibrating unit 20 defibrates the raw material shredded by thecoarse crushing unit 12. The term “defibrate” as used herein means theact of disentangling a raw material made up of fibers bound to oneanother into individual unbound pieces. In addition to the defibratingfunction, the defibrating unit 20 has a function of separating, from thefibers, resin particles adhering to the raw material, and othersubstances adhering thereto such as ink, toner, and blurring inhibitor,etc.

The output from the defibrating unit 20 is called as “defibratedmaterial”. The “defibrated material” sometimes contains, in addition todefibrated fibers, resin particles separated from the fibers in theprocess of defibration, a colorant such an ink, toner, etc., an additivesuch as blurring inhibitor, paper-strengthening agent, etc. Thedefibrated material has a string shape or a ribbon shape. The defibratedmaterial may be in a state in which it is not intertwined with any otherdefibrated fiber, that is, in an independent state. Alternatively, thedefibrated material may be in a state of so-called “lump”, in which itis intertwined with other defibrated material.

The defibrating unit 20 performs dry defibration. The term “dry” as usedherein means a method in which processing such as defibration isperformed under atmospheric conditions, for example, in air, not in aliquid. An impeller mill, for example, is used as the defibrating unit20. The defibrating unit 20 has a function of producing a flow of airfor sucking in the raw material and putting out the defibrated material.By utilizing such a self-produced flow of air, the defibrating unit 20is able to suck in the raw material through an inlet 22 together withthe airflow, perform defibration, and then transport the defibratedmaterial to an outlet 24. The defibrated material outputted from thedefibrating unit 20 is sent to the screening unit 40 through a pipe 3.The flow of air produced by the defibrating unit 20 may be used also fortransporting the defibrated material from the defibrating unit 20 to thescreening unit 40. Alternatively, an airflow producing device such as ablower may be provided, and the airflow of the blower may be used fortransporting the defibrated material from the defibrating unit 20 to thescreening unit 40.

The defibrated material defibrated by the defibrating unit 20 goes intothe screening unit 40 through an inlet 42, and is screened thereat onthe basis of fiber lengths. The screening unit 40 has, for example, adrum portion 41 and a housing portion 43. The drum portion 41 is housedin the housing portion 43. For example, a sieve is used as the drumportion 41. The drum portion 41 has a net, and is able to sort theinputted defibrated material into a first screened material and a secondscreened material. The first screened material is made up of fibers orparticles that are smaller than the meshes of the net, that is, thosewhose size is small enough to pass through the net. The second screenedmaterial is made up of fibers that are larger than the meshes of thenet, yet-to-be-defibrated pieces, and lumps, that is, those whose sizeis not small enough to pass through the net. The first screened materialis sent to the deposition unit 60 through a pipe 7. The second screenedmaterial is put out from an outlet 44 to be returned to the defibratingunit 20 through a pipe 8. Specifically, the drum portion 41 is acylindrical sieve that is driven to rotate by a motor. Examples of thenet of the drum portion 41 are: a wire net, an expanded metal net formedby pulling and expanding a metal plate having slits, and a punched metalnet formed by punching holes through a metal plate by using a punchingpress machine, etc.

The first web forming unit 45 transports, to the pipe 7, the firstscreened material outputted from the screening unit 40. For example, thefirst web forming unit 45 includes a mesh belt 46, tensioning rollers47, and a suction mechanism 48.

The suction mechanism 48 is able to suck, onto the surface of the meshbelt 46, the first screened material dispersed in air after passingthrough the opening of the screening unit 40. The first screenedmaterial accumulates on the mesh belt 46 that is moving, thereby forminginto a web V thereon. The basic configuration of the mesh belt 46, thetensioning rollers 47, and the suction mechanism 48 is the same as thatof a mesh belt 72, tensioning rollers 74, and a suction mechanism 76 ofthe second web forming unit 70 described later.

The web V formed by going through the processes performed by thescreening unit 40 and the first web forming unit 45 contains a lot ofair and is therefore soft and slightly bulky. The web V formed byaccumulation on the mesh belt 46 is put into the pipe 7 and is thentransported to the deposition unit 60.

The rotator 49 is able to cut the web V. In the illustrated example, therotator 49 has a base portion 49 a and a protruding portion 49 b. Theprotruding portion 49 b protrudes from the base portion 49 a. Theprotruding portion 49 b has, for example, a plate-like shape. In theillustrated example, the protruding portion 49 b is made up of fourprotrusions. The four protrusions 49 b are provided at equal intervals.The base portion 49 a rotates in a direction R. Due to this rotation,the protruding portion 49 b is able to rotate around the base portion 49a. By cutting the web V by the rotator 49, for example, it is possibleto reduce fluctuations in the amount of the defibrated material suppliedto the deposition unit 60 per unit time.

The rotator 49 is provided near the first web forming unit 45. In theillustrated example, the rotator 49 is provided near the tensioningroller 47 a located on the downstream position of the path of the web V.The rotator 49 is provided at a position where the protruding portion 49b is able to come into contact with the web V but does not come intocontact with the mesh belt 46 on which the web V is deposited.Therefore, it is possible to prevent the mesh belt 46 from being abradedby the protruding portion 49 b. The minimum distance between theprotruding portion 49 b and the mesh belt 46 is, for example, 0.05 mm ormore and 0.5 mm or less. With this distance, it is possible to cut theweb V without damaging the mesh belt 46.

The mixing unit 50 mixes the first screened material, which has passedthrough the net of the screening unit 40, with an additive that containsresin. The mixing unit 50 includes, for example, an additive supplyportion 52, which supplies the additive, a pipe 54, through which thefirst screened material and the additive are transported, and a blower56. In the illustrated example, the additive is supplied from theadditive supply portion 52 into the pipe 54 via a hopper 9. The pipe 54is connected from the pipe 7.

In the mixing unit 50, the blower 56 produces a flow of air, and thefirst screened material and the additive are transported while beingmixed with each other inside the pipe 54. The mechanism for mixing thefirst screened material with the additive is not specifically limited.For example, a propeller that rotates at a high speed may be used forstirring them. A pipe having internal blades may rotate to behave assuch a mixer.

A screw feeder illustrated in FIG. 1, or a disk feeder that is notillustrated, etc. can be used as the additive supply portion 52. Theadditive supplied from the additive supply portion 52 contains resin forbonding the fibers to one another. At the point in time of the supply ofthe resin, the fibers have not been bonded yet. The resin melts duringthe process of passing through the sheet forming unit 80. The moltenresin bonds the fibers together.

The resin supplied from the additive supply portion 52 is thermoplasticresin or thermosetting resin. Examples of this resin are: AS(Acrylonitrile Styrene) resin, ABS (Acrylonitrile Butadiene Styrene)resin, polypropylene, polyethylene, polyvinyl chloride, polystyrene,acrylic resin, polyester, polyethylene terephthalate, polyphenyleneether, polybutylene terephthalate, nylon, polyamide, polycarbonate,polyacetal, polyphenylene sulfide, polyetherether ketone, and the like.Any of these kinds of resin may be used alone, or a mixture of any ofthem may be used. The additive supplied from the additive supply portion52 may be fibrous or powdery.

The additive supplied from the additive supply portion 52 may contain,in addition to the binder resin for bonding the fibers together, acolorant for coloring the fibers, an agglomeration inhibitor forinhibiting the agglomeration of the fibers, an aggregation inhibitor forinhibiting the aggregation of resin molecules, a flame retardant thatmakes the fibers, etc. incombustible, depending on the type of sheets tobe manufactured. The mixture outputted from the mixing unit 50 is sentto the deposition unit 60 through the pipe 54.

The mixture outputted from the mixing unit 50 goes into the depositionunit 60 through an inlet 62. The deposition unit 60 disentangles theintertwined defibrated material, and lets them fall while dispersingthem in air. If the resin of the additive supplied from the additivesupply portion 52 is fibrous, the deposition unit 60 disentangles theintertwined resin. By this means, the deposition unit 60 is able to forma uniform deposition of the mixture on the second web forming unit 70.

The deposition unit 60 has, for example, a drum portion 61 and a housingportion 63. The drum portion 61 is housed in the housing portion 63. Arotatable cylindrical sieve is used as the drum portion 61. The drumportion 61 has a net, and lets fibers or particles that are smaller thanthe meshes of the net fall among those included in the mixture outputtedfrom the mixing unit 50. The structure of the drum portion 61 is, forexample, the same as the structure of the drum portion 41.

The “sieve” of the drum portion 61 does not necessarily have to have anyparticular target screening function. That is, the “sieve” used as thedrum portion 61 just means a mechanism equipped with a net, and the drumportion 61 may let all of those included in the mixture inputted intothe drum portion 61 fall.

The second web forming unit 70 forms a web W by deposition of the outputfrom the deposition unit 60 on itself. The second web forming unit 70includes, for example, the aforementioned mesh belt 72, tensioningrollers 74, and suction mechanism 76.

The material having passed through the opening of the deposition unit 60accumulates on the mesh belt 72. The mesh belt 72 is stretched aroundthe tensioning rollers 74. The mesh belt 72 is permeable to air, but isnot permeable to the material having passed through the opening of thedeposition unit 60. The mesh belt 72 moves due to the rotation of thetensioning rollers 74. The material having passed through the opening ofthe deposition unit 60 falls and accumulates one after another while themesh belt 72 moves continuously. As a result, the web W is formed on themesh belt 72.

The suction mechanism 76 is provided under the mesh belt 72. The suctionmechanism 76 is able to produce a downward flow of air. Because of theairflow produced by the suction mechanism 76, it is possible to suck themixture dispersed in air by the deposition unit 60 onto the mesh belt72. By this means, it is possible to increase the speed of dischargefrom the deposition unit 60. Moreover, it is possible to form a downwardflow, by the suction mechanism 76, in the path of fall of the mixture;therefore, it is possible to prevent the defibrated material and theadditive from becoming entangled while they fall.

Since the web W is formed by going through the processes performed bythe deposition unit 60 and the second web forming unit 70 as describedabove, the web W contains a lot of air and is therefore soft andslightly bulky. The web W formed by deposition on the mesh belt 72 istransported to the sheet forming unit 80.

In the illustrated example, a moisture adjusting unit 78 for adjustingthe moisture of the web W is provided. The moisture adjusting unit 78 isable to adjust ambient humidity and the ratio of the web W to water byadding the water, water vapor, or mist to the web W.

The sheet forming unit 80 forms a sheet S by pressing and heating theweb W, which has been formed by deposition on the mesh belt 72. At thesheet forming unit 80, heat is applied to the mixture of the defibratedmaterial and the additive in the web W. By this means, it is possible tobond the fibers contained in the mixture to one another by means of theadditive.

The sheet forming unit 80 includes a pressing portion 82, which pressesthe web W, and a heating portion 84, which heats the web W pressed bythe pressing portion 82. The pressing portion 82 is made up of a pair ofrollers 85. The pressing portion 82 applies pressure to the web W. Thepressing decreases the thickness of the web W and increases the bulkdensity of the web W. Heating rollers, a heat press shaping machine, hotplates, a hot air blower, an infrared heater, or a flash fixationdevice, for example, can be used as the heating portion 84. In theillustrated example, the heating portion 84 has a pair of heatingrollers 86. Since the heating portion 84 is configured as the heatingrollers 86, as compared with a case where the heating portion 84 isconfigured as a plate-type pressing device, it is possible to shape thesheet S while transporting the web continuously. The rollers 85 and theheating rollers 86 are arranged such that, for example, their rotationshafts are in parallel with one another. The rollers 85 are able toapply, to the web W, pressure that is higher than pressure applied bythe heating rollers 86 to the web W. The number of the rollers 85 is notspecifically limited. The number of the heating rollers 86 is also notspecifically limited.

The cutting unit 90 cuts the sheet S produced by the sheet forming unit80. In the illustrated example, the cutting unit 90 includes a firstcutting portion 92, which cuts the sheet S in the direction orthogonalto the direction of transportation of the sheet S, and a second cuttingportion 94, which cuts the sheet S in the direction parallel to thetransportation direction. For example, the second cutting portion 94cuts the sheet S having passed through the first cutting portion 92.

The sheet S that has predetermined single-cut size is produced throughthe above process. The single-cut sheet S is ejected to an ejected sheetreceiver 96.

1.1.2. Putting-Out Unit

The fibrous body manufacturing apparatus 100 includes a putting-out unit110. Each of FIGS. 2 and 3 is a schematic view of the putting-out unit110 of the fibrous body manufacturing apparatus 100. To facilitate anexplanation, in FIG. 1, the illustration of the putting-out unit 110 issimplified. A state after a predetermined time has elapsed from a stateillustrated in FIG. 2 is illustrated in FIG. 3.

As illustrated in FIGS. 1, 2, and 3, for example, the putting-out unit110 includes a first supplying roll 120, a first placing portion 130,and a second placing portion 140. The putting-out unit 110 puts a groundsheet 150 out onto the mesh belt 72. The mesh belt 72 is an example of atransportation unit that transports the ground sheet 150 put out ontoitself.

The first supplying roll 120 is a roll of a base sheet 152. The firstsupplying roll 120 rotates in a direction Q1 when driven by a drivingmechanism that is not illustrated. Due to this rotation, the base sheet152 constituting the first supplying roll 120 is unreeled therefrom andmoves toward the mesh belt 72. In the example illustrated in FIGS. 2 and3, the unreeled part of the first supplying roll 120 is placed on atable 122. In FIG. 1, the table 122 is not illustrated. The base sheet152 has one side 152 a and the other side 152 b, which is the oppositesurface in relation to the one side 152. The other side 152 b is incontact with the mesh belt 72. The material of the base sheet 152 willbe described later.

The first placing portion 130 places a functional member 154 on the oneside 152 a of the base sheet 152. The first placing portion 130includes, for example, a second supplying roll 132, rollers 134, a guide136, and a cutter 138.

The second supplying roll 132 is a roll of the functional member 154,which has a sheet shape when not rolled. The second supplying roll 132rotates in a direction Q2 when driven by a driving mechanism that is notillustrated. In the illustrated example, the direction Q2 is theopposite of the direction Q1. As illustrated in FIG. 2, the functionalmember 154 constituting the second supplying roll 132 travels throughthe rollers 134 and the guide 136 and is placed on the one side 152 a ofthe base sheet 152. Then, as illustrated in FIG. 3, the functionalmember 154 is cut by the cutter 138 at a predetermined position. Thematerial of the functional member 154 will be described later.

The second placing portion 140 places an adhesive tape 156 on the oneside 152 a of the base sheet 152. By doing so, the second placingportion 140 temporarily fixes a part of the functional member 154 ontothe base sheet 152. The second placing portion 140 includes, forexample, a third supplying roll 142, a cutter 144, and a base collectingroll 146.

The third supplying roll 142 is a roll of the adhesive tape 156, whichhas a sheet shape when not rolled. The adhesive tape 156 has a layeredstructure that includes a base 156 a and a sticky portion 156 b. Thethird supplying roll 142 rotates in a direction Q3, with the stickyportion 156 b of the adhesive tape 156 pressed against the one side 152a of the base sheet 152. Due to this rotation, the adhesive tape 156 isunreeled by a predetermined length, the base 156 a and the stickyportion 156 b are separated from each other by the cutter 144, and thebase 156 a is reeled onto the base collecting roll 146. In theillustrated example, the direction Q3 is the opposite of the directionQ1. The sticky portion 156 b of the adhesive tape 156, which constitutesthe third supplying roll 142, is placed while temporarily fixing thefunctional member 154 to the one side 152 a of the base sheet 152. Then,the adhesive tape 156 is cut by the cutter 144 at a predeterminedposition. The material of the adhesive tape 156 will be described later.

The putting-out unit 110 having the configuration described above putsthe ground sheet 150 out onto the mesh belt 72, with the functionalmember 154 placed on the one side 152 a of the base sheet 152. Asillustrated in FIG. 1, the mesh belt 72 transports the ground sheet 150put out onto itself, and the deposition unit 60 lets the mixture thatincludes the fibers and the binder fall and accumulate on one side 150 aof the ground sheet 150 transported by the mesh belt 72, thereby formingthe web W thereon. The suction mechanism 76, which is an example of asucking unit, is provided below the other side 150 b of the ground sheet150. The sheet forming unit 80 is an example of a pressing and heatingunit that applies pressure and heat to the web W. The one side 150 a ofthe ground sheet 150 is oriented in the same direction as the one side152 a of the base sheet 152.

1.2. Sheet

Next, with reference to the accompanying drawings, the sheet Smanufactured by the fibrous body manufacturing apparatus 100 describedabove will now be explained. FIG. 4 is a schematic plan view of thesheet S according to the first embodiment. FIG. 5 is a schematiccross-sectional view of the sheet S according to the first embodiment,taken along the line V-V of FIG. 4.

The sheet S is a rectangular fibrous body cut by the cutting unit 90into the size of, for example, A4. The sheet S is used as printingpaper, and printing is performed thereon by a printer, similarly toplain paper, etc. The sheet S has a thickness of, for example, 50 μm ormore and 200 μm or less. Preferably, the sheet S may have a thickness of90 μm or more and 150 μm or less.

As illustrated in FIGS. 4 and 5, the sheet S includes the ground sheet150 and a surface layer sheet 160. The ground sheet 150 includes thebase sheet 152, the functional member 154, and the sticky portion 156 b.The sheet S is a functional sheet that includes the functional member154. To facilitate an explanation, in FIG. 4, the surface layer sheet160 is illustrated in a see-through state.

The base sheet 152 is made of, for example, nonwoven fabric. Preferably,the nonwoven fabric of the base sheet 152 may be made up of fibers thathave the same molecular structure as that of fibers discharged from thedeposition unit 60. Examples of the fibers contained in the base sheet152 are: cellulose fibers, rayon, cotton, linters, kapok, flax, hemp,and ramie. Any one of those enumerated here may be used alone, or two ormore of them may be used in combination. A preferred example of thefibers contained in the base sheet 152 is cellulose fibers. Cellulosefibers are easily available and have excellent formability. Preferably,the cellulose fibers may be fibers derived from wood-based pulp.Examples of the wood-based pulp are: virgin pulp, Kraft pulp, bleachedchemi-thermo mechanical pulp, synthetic pulp, or pulp derived from wastepaper or recycled paper. Any one of those enumerated here may be usedalone, or two or more of them may be used in combination.

The base sheet 152 is permeable to air. The term “air permeability” asused herein means the property of allowing air to pass through aplurality of pores. Preferably, the Gurley second, which indicates thedegree of air permeability, of the base sheet 152 may be 30 seconds orless when measured using a Gurley permeability tester. More preferably,the Gurley second of the base sheet 152 may be 15 seconds or less.

The functional member 154 is disposed on the one side 152 a of the basesheet 152. Specifically, the functional member 154 is bonded to the oneside 152 a of the base sheet 152 by an adhesive layer 157. Thefunctional member 154 is, for example, a magnetic body made of amagnetic material. Specifically, the functional member 154 is a magneticwire made of a magnetic material and having a length in the order ofseveral millimeters or more. The sheet S includes, for example, aplurality of functional members 154. In the example illustrated in FIG.4, the sheet S includes six functional members 154. These functionalmembers 154 are arranged radially in a plan view. These functionalmembers 154 do not overlap with one another in a plan view. In theexample illustrated in FIG. 4, among the six functional members 154,functional members 154 a and 154 b have their longitudinal direction ina first direction, functional members 154 c and 154 d have theirlongitudinal direction in a second direction, which is inclined by 60°with respect to the first direction, and functional members 154 e and154 f have their longitudinal direction in a third direction, which isinclined by 60° with respect to the first and second directions. Thefunctional member 154 a does not overlap with another functional member154 b in a plan view. For example, by moving the first placing portion130 and the second placing portion 140 with respect to the base sheet152 by a moving mechanism that is not illustrated, it is possible toarrange the functional members 154 at predetermined positions.

Since the sheet S includes the functional member 154 that is a magneticwire, the sheet S can be used as security paper. The security paper is amedium realized in the form of paper detectable by a detection systemequipped with an exciting coil and a detecting coil. An alternatingcurrent is applied to the exciting coil to generate an alternatingmagnetic field, and the sheet S is placed in the alternating magneticfield. It is possible to detect the presence of the sheet S whenmagnetization reversal occurs. Therefore, by disposing the exciting coiland the detecting coil in a gate where persons or vehicles are able topass, it is possible to detect the sheet S carried through the gate.Accordingly, it is possible to detect an unauthorized act of carryingthe sheet S out. For example, if confidential information, etc. isprinted on the sheet S, it is possible to prevent the leakage of theconfidential information.

It is preferable if the functional member 154 exhibits a largeBarkhausen effect. Specifically, the material of the functional member154 is FeCr-based, FeCo-based, FeNi, FeSiB, or FeCoSiB-based alloy.These materials can be used suitably because they exhibit a largeBarkhausen effect even without applying strain by post processing.Strain may be applied by post processing so as to impart largeBarkhausen properties. The functional member 154 may be a wire formed bycutting an amorphous ribbon. The functional member 154 may be aglass-coated wire formed by drawing such amorphous metal together withglass from a molten state and by cooling them.

Preferably, the functional member 154 may have a longitudinally-longline-like shape such as a wire shape or a ribbon shape. Having apredetermined length relative to a cross-sectional area size makes iteasier to exhibit a large Barkhausen effect.

Preferably, the diameter of the functional member 154 may be 10 μm ormore and 100 μm or less when the functional member 154 has a wire shape.If the functional member 154 has a diameter of 10 μm or more, it iseasier to exhibit a large Barkhausen effect. If the functional member154 has a diameter of 100 μm or less, the functional member 154 does notbecome exposed from the sheet S. Moreover, if the functional member 154has a diameter of 100 μm or less, it is possible to cut the functionalmember 154 with the cutter 138 easily.

Preferably, the thickness of the functional member 154 may be 10 μm ormore and 100 μm or less when the functional member 154 has a ribbonshape. If the functional member 154 has a thickness of 10 μm or more, itis easier to exhibit a large Barkhausen effect. If the functional member154 has a thickness of 100 μm or less, the functional member 154 doesnot become exposed from the sheet S. Moreover, if the functional member154 has a thickness of 100 μm or less, it is possible to cut thefunctional member 154 with the cutter 138 easily. Preferably, the widthof the functional member 154 may be, for example, 50 μm or more and1,000 μm or less when the functional member 154 has a ribbon shape.

Preferably, the length of the functional member 154 may be 10 mm ormore, or more preferably, 50 mm or more, when the functional member 154has a wire shape or a ribbon shape. If the length of the functionalmember 154 is 10 mm or more, in synergy with the effect of shapeanisotropy, it is easier to exhibit an NS reversal effect. Moreover, ifthe length of the functional member 154 is 10 mm or more, it is easierto place the functional member 154 at a desired position. There is noupper limit in the length of the functional member 154 except that it isnot greater than the size of the cut sheet S. For example, the length ofthe functional member 154 is 200 mm or less.

With regard to the diameter and the length of the functional member 154,it is preferable if the diameter and the length of all of the functionalmembers 154 included in the sheet S are within the ranges describedabove. However, if there is a distribution in the values of them, it ispreferable if the average of the values of the diameter of them and theaverage of the values of the length of them are within the rangesdescribed above. If the functional member 154 is bent, the minimumdistance from one end of the functional member 154 to the other endthereof is defined as the length of the functional member 154.

It is possible to numerically define the functional members 154 in termsof, for example, weight in the sheet S cut by the cutting unit 90. Forexample, if the weight of the sheet S is expressed as 100 parts byweight, preferably, the weight of the functional member 154 may be 1.0part by weight or less. In other words, the fibrous body manufacturingapparatus 100 manufactures the sheet S by performing cutting by thecutting unit 90 at a position where the weight of the functional member154 is 1.0 part by weight or less when the weight of the sheet S is 100parts by weight.

The sticky portion 156 b is provided on the functional member 154. Inthe illustrated example, the sticky portion 156 b made up of two stickyparts is provided on each one functional member 154. The sticky portion156 b is provided on one end and the other end of the functional member154. The number of the sticky parts constituting the sticky portion 156b on each functional member 154 is not specifically limited. However, byproviding the sticky portion 156 b on one end and the other end of thefunctional member 154, it is possible to flexibly accommodate thestretching of the base sheet 152. The sticky portion 156 b is theportion that remains after the removal of the base 156 a from theadhesive tape 156. The sticky portion 156 b is, for example, a so-calledcorrection tape. The sticky portion 156 b includes the adhesive layer157 and a concealing layer 158.

The adhesive layer 157 bonds the functional member 154 to the base sheet152. The adhesive layer 157 bonds the concealing layer 158 and thefunctional member 154 to the one side 152 a of the base sheet 152. Thematerial of the adhesive layer 157 is, for example, a natural rubberadhesive. Specifically, a tackifier and an oxidation inhibitor are addedto natural rubber.

The concealing layer 158 is provided on the surface 157 a of theadhesive layer 157. The concealing layer 158 hides the adhesive layer157. That is, the concealing layer 158 makes it difficult for theadhesive layer 157 to be seen when viewed from the side where the oneside 150 a of the ground sheet 150 is present. The material of theconcealing layer 158 is, for example, a mixture of methyl cyclohexaneserving as a solvent, acrylic resin serving as a fixing agent, andtitanium oxide serving as a pigment. The color of the concealing layer158 is white because it contains titanium oxide, which is a whitepigment. Therefore, when the color of the base sheet 152 and the colorof the surface layer sheet 160 are white, this makes the concealinglayer 158 hard to spot. The concealing layer 158 does not haveadhesiveness.

The pigment contained in the concealing layer 158 can be selected tosuit the color of the base sheet 152 and the color of the surface layersheet 160. The solvent and the fixing agent contained in the concealinglayer 158 can be selected to suit the pigment contained in theconcealing layer 158.

Preferably, the concealing layer 158 and the adhesive layer 157 may bepermeable to air. Each of the concealing layer 158 and the adhesivelayer 157 is able to allow air to pass through a plurality of pores. Thepermeability of the concealing layer 158 and the adhesive layer 157makes it easier to suck the fibers and the binder from the depositionunit 60 by the suction mechanism 76.

When the adhesive tape 156 is prepared in a roll shape as illustrated inFIG. 2, preferably, the adhesive tape 156 and a non-illustrated basetape may be formed into a roll in a stacked state. When the functionalmember 154 is to be temporarily fixed with the adhesive tape 156, thenon-illustrated base tape should preferably be taken off the adhesivetape 156. This makes it possible to feed the adhesive tape 156 preparedin a roll shape onto the base sheet 152 easily.

The surface layer sheet 160 is provided on the one side 150 a of theground sheet 150. The base sheet 152, the functional member 154, and theadhesive tape 156 are covered by the surface layer sheet 160. Thesurface layer sheet 160 contains the fibers of the raw material suppliedby the supplying unit 10 and the binder that is the resin supplied fromthe additive supply portion 52. The fibers and the binder contained inthe surface layer sheet 160 are those discharged from the depositionunit 60. By being heated by the heating portion 84, the binder bonds thefibers discharged from the deposition unit 60 together and bonds, to thebase sheet 152, the fibers discharged from the deposition unit 60. Inaddition, the binder bonds the functional member 154 and the base sheet152 to each other. Furthermore, the binder bonds, to the functionalmember 154, the fibers discharged from the deposition unit 60.

In the example illustrated in FIG. 4, the functional members 154 arearranged radially. However, the arrangement of the functional members154 is not limited to such a radial layout. The arrangement of thefunctional members 154 may be modified as long as they do not overlapwith one another. For example, in a state in which the functionalmembers 154 a and 154 b have their longitudinal direction in the firstdirection, the functional members 154 c and 154 d have theirlongitudinal direction in the second direction, and the functionalmembers 154 e and 154 f have their longitudinal direction in the thirddirection, the functional members 154 may be arranged in such a way asto surround the center of the base sheet 152 as illustrated in FIG. 6.Alternatively, the functional members 154 may be arranged randomly asillustrated in FIG. 7. By arranging the functional members 154 in such away as to have different longitudinal directions, it is possible to makethe functional members 154 easier to be detected, for example, ascompared with a case where the functional members 154 have the samelongitudinal direction.

The functional member 154 has been described as a magnetic body above.However, the functional member 154 does not have to be a magnetic bodyas long as the functional member 154 in the sheet S is detectable byexternal contact-less detection. For example, the functional member 154may be a metallic wire configured to be detected by a metal detector.The functional member 154 may be an RF (Radio Frequency) tag configuredto be detected by an RFID (Radio Frequency Identification) reader. Thefunctional member 154 may be an IC (Integrated Circuit) chip.

The sheet S may have a structure formed by providing a non-illustratednonwoven fabric sheet on the surface of the surface layer sheet 160. Toput it another way, the surface layer sheet 160 may be located betweenthe base sheet 152 and the nonwoven fabric sheet. However, omitting sucha sheet made of nonwoven fabric will be advantageous for reducing cost.

1.3. Method for Manufacturing Sheet

Next, with reference to the accompanying drawings, a method formanufacturing the sheet S according to the first embodiment will now beexplained. FIG. 8 is a flowchart for explaining a method formanufacturing the sheet S according to the first embodiment. The sheet Sis manufactured using, for example, the fibrous body manufacturingapparatus 100 described above.

As illustrated in FIG. 8, the method for manufacturing the sheet Sincludes a putting-out process (step S1), a transportation process (stepS2), a deposition process (step S3), and a pressing and heating process(step S4). The putting-out process (step S1) is a process of putting theground sheet 150 out, with the functional member 154 placed on the oneside 152 a of the base sheet 152. The transportation process (step S2)is a process of transporting the ground sheet 150 having been put out.The deposition process (step S3) is a process of letting the fibers andthe binder deposit on the one side 150 a of the transported ground sheet150, thereby forming the web W thereon. The pressing and heating process(step S4) is a process of applying pressure and heat to the web W.

The putting-out process (step S1) is executed by the putting-out unit110 of the fibrous body manufacturing apparatus 100. The transportationprocess (step S2) is executed by the mesh belt 72. The depositionprocess (step S3) is executed by the deposition unit 60. The pressingand heating process (step S4) is executed by the sheet forming unit 80,which includes the pressing portion 82 and the heating portion 84.

In addition to the processes described above, the method formanufacturing the sheet S may include other processes executed by thecomponents of the fibrous body manufacturing apparatus 100 describedabove.

1.4. Operational Effects

The fibrous body manufacturing apparatus 100 includes the putting-outunit 110, which puts the ground sheet 150 out, with the functionalmember 154 placed on the one side 152 a of the base sheet 152, the meshbelt 72, which transports the ground sheet 150 put out onto itself, thedeposition unit 60, which lets the fibers and the binder deposit on theone side 150 a of the transported ground sheet 150, thereby forming theweb W thereon, and the sheet forming unit 80, which applies pressure andheat to the web W. As described above, the fibrous body manufacturingapparatus 100 manufactures the sheet S, with the functional members 154sandwiched between the base sheet 152 and the pressed and heated web W(the surface layer sheet 160). For this reason, the fibrous bodymanufacturing apparatus 100 is able to manufacture the sheet S that hasa low risk of exposure of the functional member 154 on its surface evenif, for example, the sheet S is bent or folded. Therefore, the sheet Smanufactured by the fibrous body manufacturing apparatus 100 has highprintability.

Moreover, the sheet S manufactured by the fibrous body manufacturingapparatus 100 offers higher print performance because printing isperformed on its surface layer sheet 160 containing fibers, as comparedwith a case where, for example, printing is performed on a coat layer (acoat layer not containing fibers) provided on a sheet surface for thepurpose of preventing a functional member from becoming exposed.

The fibrous body manufacturing apparatus 100 includes the suctionmechanism 76, which is provided below the other side 150 b of the groundsheet 150. The base sheet 152 is permeable to air. Therefore, in thefibrous body manufacturing apparatus 100, it is easier to suck thefibers and the binder from the deposition unit 60 by the suctionmechanism 76, as compared with a case where the base sheet 152 is notpermeable to air.

In the fibrous body manufacturing apparatus 100, the functional member154 is bonded to the base sheet 152 by the adhesive layer 157, and theconcealing layer 158 for hiding the adhesive layer 157 is provided onthe surface 157 a of the adhesive layer 157. Therefore, in the fibrousbody manufacturing apparatus 100, as compared with a case where noconcealing layer is provided, such a concealing structure makes itdifficult for the adhesive layer 157 to be seen when viewed from theside where the one side 150 a of the ground sheet 150 is present.Moreover, it is possible to reduce the risk of movement of thefunctional member 154 in relation to the base sheet 152 during themovement of the ground sheet 150.

For example, if a liquid adhesive is used for the bonding of thefunctional member, the adhesive will seep into the base sheet andspreads, resulting in a stain. Such a stain is obstructive to printing.If a wax is used for the bonding of the functional member, the wax willmelt when heated by the heating portion, resulting in a stain, as is thecase with a liquid adhesive. In the fibrous body manufacturing apparatus100, it is possible to avoid the above problems because the adhesivelayer 157 is used for the bonding.

The fibrous body manufacturing apparatus 100 includes the defibratingunit 20, which defibrates a raw material to form a defibrated materialcontaining fibers, and the mixing unit 50, which forms a mixture bymixing the defibrated material with a binder. The deposition unit 60lets the mixture deposit. Therefore, the fibrous body manufacturingapparatus 100 is able to let the mixture containing the defibratedmaterial and the binder deposit on the mesh belt 72.

In the fibrous body manufacturing apparatus 100, another functionalmember 154 b is arranged on the one side 152 a of the base sheet 152,and the functional member 154 a and this another functional member 154 bdo not overlap with each other. Therefore, the fibrous bodymanufacturing apparatus 100 is able to manufacture the sheet S that hasa higher degree of flatness as compared with a case where a functionalmember and another functional member overlap with each other.

In the fibrous body manufacturing apparatus 100, the putting-out unit110 includes the first placing portion 130, which arranges thefunctional members 154 on the base sheet 152. Therefore, the fibrousbody manufacturing apparatus 100 is able to manufacture the ground sheet150.

2. Second Embodiment

Next, with reference to the accompanying drawings, a fibrous bodymanufacturing apparatus according to a second embodiment will now beexplained. FIG. 9 is a schematic view of a fibrous body manufacturingapparatus 200 according to a second embodiment.

In the description of the fibrous body manufacturing apparatus 200according to the second embodiment below, the same reference numeralsare assigned to components having the same functions as those of thefibrous body manufacturing apparatus 100 according to the firstembodiment described above, and a detailed explanation of them isomitted.

In the fibrous body manufacturing apparatus 100 described above, asillustrated in FIG. 1, the putting-out unit 110 includes the firstplacing portion 130 and the second placing portion 140. By contrast, inthe fibrous body manufacturing apparatus 200, as illustrated in FIG. 9,the putting-out unit 110 does not include the first placing portion 130and the second placing portion 140.

In the fibrous body manufacturing apparatus 200, the putting-out unit110 includes a cabinet portion 210 inside which the ground sheet 150 ishoused. The ground sheet 150, when housed, is in the shape of a roll.Namely, the first supplying roll 120 housed inside the cabinet portion210 is a roll of the ground sheet 150. The cabinet portion 210, togetherwith the ground sheet 150, is replaceable. Therefore, the user is ableto select a desired ground sheet 150 and install the cabinet portion 210onto the fibrous body manufacturing apparatus 200. In the fibrous bodymanufacturing apparatus 200, the putting-out unit 110 includes thecabinet portion 210 inside which the ground sheet 150 is housed, and theground sheet 150, when housed, is in the shape of a roll. Therefore, itis unnecessary to provide the placing portions 130 and 140, resulting ina compact apparatus configuration.

The foregoing exemplary embodiments and the modification examples arejust examples. The scope of the present disclosure is not limited tothese examples. For example, the foregoing exemplary embodiment(s) andthe modification example(s) may be combined as needed.

The present disclosure encompasses every structure that is substantiallythe same as the structure described in the foregoing exemplaryembodiments, for example, structure with the same function, method, andresult, or structure with the same object and effect. The presentdisclosure encompasses every structure that is obtained by replacementof a non-essential part(s) in the structure described in the foregoingexemplary embodiments. The present disclosure encompasses everystructure that produces the same operational effect as that of thestructure described in the foregoing exemplary embodiments, or structurethat achieves the same object as that of the structure described in theforegoing exemplary embodiments. The present disclosure encompassesevery structure that is obtained by addition of known art to thestructure described in the foregoing exemplary embodiments.

The following content of disclosure can be derived from the foregoingexemplary embodiments and modification examples.

A fibrous body manufacturing apparatus according to a certain aspect ofthe disclosed embodiments includes: a putting-out unit that puts aground sheet out, with a functional member arranged on one side of asheet; a transportation unit that transports the ground sheet put outonto itself; a deposition unit that lets fibers and a binder deposit onone side of the transported ground sheet, thereby forming a web thereon;and a pressing and heating unit that applies pressure and heat to theweb.

The fibrous body manufacturing apparatus according to the above aspectmanufactures a sheet, with functional members sandwiched between a basesheet and a pressed and heated web. For this reason, it is possible tomanufacture the sheet that has a low risk of exposure of the functionalmember on its surface even if, for example, the sheet is bent or folded.

The fibrous body manufacturing apparatus according to the above aspectmay further include a sucking unit provided on a side where the otherside of the ground sheet is present; wherein the sheet may be permeableto air.

Having this structure, the fibrous body manufacturing apparatusaccording to the above aspect makes it easier to suck the fibers and thebinder from the deposition unit by the sucking unit.

In the fibrous body manufacturing apparatus according to the aboveaspect, the functional member may be bonded to the sheet by an adhesivelayer, and a concealing layer for hiding the adhesive layer may beprovided on a surface of the adhesive layer.

This structure of the fibrous body manufacturing apparatus according tothe above aspect makes it difficult for the adhesive layer to be seenwhen viewed from the side where the one side of the ground sheet ispresent.

The fibrous body manufacturing apparatus according to the above aspectmay further include: a defibrating unit that defibrates a raw materialto form a defibrated material containing fibers; and a mixing unit thatforms a mixture by mixing the defibrated material with the binder;wherein the deposition unit may let the mixture deposit.

Having this structure, the fibrous body manufacturing apparatusaccording to the above aspect is able to let the mixture containing thedefibrated material and the binder deposit on the transportation unit.

In the fibrous body manufacturing apparatus according to the aboveaspect, another functional member may be arranged on the one side of thesheet, and the functional member and the another functional member maybe configured not to overlap with each other.

Having this structure, the fibrous body manufacturing apparatusaccording to the above aspect is able to manufacture a sheet that has ahigher degree of flatness.

In the fibrous body manufacturing apparatus according to the aboveaspect, the putting-out unit may include an arranging unit that arrangesthe functional member on the sheet.

Having this structure, the fibrous body manufacturing apparatusaccording to the above aspect is able to manufacture a ground sheet.

In the fibrous body manufacturing apparatus according to the aboveaspect, the putting-out unit may include a housing unit inside which theground sheet is housed, and the ground sheet, when housed, may be in ashape of a roll.

Having this structure, the fibrous body manufacturing apparatusaccording to the above aspect makes it unnecessary to provide anarranging unit. Therefore, the fibrous body manufacturing apparatushaving this structure is compact.

A fibrous body manufacturing method according to a certain aspect of thedisclosed embodiments includes: putting a ground sheet out, with afunctional member arranged on one side of a sheet; transporting theground sheet put out; letting fibers and a binder deposit on one side ofthe transported ground sheet, thereby forming a web thereon; andpressing and heating the web.

A ground sheet according to a certain aspect of the disclosedembodiments is to be used by a fibrous body manufacturing apparatus andincludes: a sheet; and a functional member arranged on one side of thesheet; wherein the ground sheet has a roll shape.

A functional sheet according to a certain aspect of the disclosedembodiments includes: a sheet; a functional member; an adhesive layerthat bonds the functional member to the sheet; and a concealing layerprovided on a surface of the adhesive layer and configured to hide theadhesive layer.

What is claimed is:
 1. A fibrous body manufacturing apparatus,comprising: a putting-out unit that puts a ground sheet out, with afunctional member arranged on one side of a sheet; a transportation unitthat transports the ground sheet put out onto itself; a deposition unitthat lets fibers and a binder deposit on one side of the transportedground sheet, thereby forming a web thereon; and a pressing and heatingunit that applies pressure and heat to the web.
 2. The fibrous bodymanufacturing apparatus according to claim 1, further comprising: asucking unit provided on a side where an other side of the ground sheetis present; wherein the sheet is permeable to air.
 3. The fibrous bodymanufacturing apparatus according to claim 1, wherein the functionalmember is bonded to the sheet by an adhesive layer, and a concealinglayer for hiding the adhesive layer is provided on a surface of theadhesive layer.
 4. The fibrous body manufacturing apparatus according toclaim 1, further comprising: a defibrating unit that defibrates a rawmaterial to form a defibrated material containing fibers; and a mixingunit that forms a mixture by mixing the defibrated material with thebinder; wherein the deposition unit lets the mixture deposit.
 5. Thefibrous body manufacturing apparatus according to claim 1, whereinanother functional member is arranged on the one side of the sheet, andthe functional member and the another functional member do not overlapwith each other.
 6. The fibrous body manufacturing apparatus accordingto claim 1, wherein the putting-out unit includes an arranging unit thatarranges the functional member on the sheet.
 7. The fibrous bodymanufacturing apparatus according to claim 1, wherein the putting-outunit includes a housing unit inside which the ground sheet is housed,and the ground sheet, when housed, is in a shape of a roll.
 8. A fibrousbody manufacturing method, comprising: putting a ground sheet out, witha functional member arranged on one side of a sheet; transporting theground sheet put out; letting fibers and a binder deposit on one side ofthe transported ground sheet, thereby forming a web thereon; andpressing and heating the web.
 9. A ground sheet to be used by a fibrousbody manufacturing apparatus, the ground sheet comprising: a sheet; anda functional member arranged on one side of the sheet; wherein theground sheet has a roll shape.
 10. A functional sheet, comprising: asheet; a functional member; an adhesive layer that bonds the functionalmember to the sheet; and a concealing layer provided on a surface of theadhesive layer and configured to hide the adhesive layer.